ArmaFORM PET - the green PET

Transcription

1 ArmaFORM PET - the green PET With the market introduction of ArmaFORM PET, Armacell paved the way for PET foam cores in the composite industry. But our research did not stop there; as a technology leader, the Armacell global R&D invested several years in the development of a technology that enables the production of structural PET foam boards with consistent, reliable qualities 100% made from post-consumer PET materials, more precisely from recycled beverage bottles. ArmaFORM PET in the ecological cycle PET material collection Sorting, crushing,... to flakes PET granulation process Extrusion foaming process Use in a variety of applications ArmaFORM can be 100% recycled Our unique green PET foam meets not only stringent technical requirements of today s composite core materials but also follows the guidelines for circular economy and helps to preserve and enhance the human environment. We are proud to say that ArmaFORM PET outperforms any other structural foam core in the composite industry in terms of environmental benefits, whether competing PET foam or other polymeric foams like PVC, SAN or PUR: ArmaFORM PET GR savings on CO 2 emisson In addition to its sustainable raw material base, ArmaFORM PET is manufactured according to an energy and resource-optimized production process: ArmaForm PET > No ozone depleting HFC / CFC blowing agents > Only halogen-free flame retarded additives > 100% re-use of material loss during production Further more ArmaFORM PET is fully recyclable at its life cycle end and could be reprocessed into full value raw material if removed properly. -33% vs. standard PET -52% vs. PVC -46% vs. SAN -62% vs. PUR Savings on CO2 emission per kilo foamed product. More detailed information is provided in our technical bulletin Life Cycle Assessment. ArmaFORM PET is not only green in color, it is a truly sustainable solution. It provides all the known benefits of PET-based structural foams, such as thermal resistance, fatigue behavior, compressive strength, and enables Armacell and its customers to present a real green alternative to standard PET foams and other foam core materials currently available in the market. Armacell provides this information as a technical service. To the extent the information is derived from sources other than Armacell, Armacell is substantially, if not wholly, relying upon the other source(s) to provide accurate information. Information provided as a result of Armacell s own technical analysis and testing is accurate to the extent of our knowledge and ability, using effective standardized methods and procedures. Each user of these products, or information, should perform their own tests to determine the safety, fitness and suitability of these products, or combination of products, for any foreseeable purposes, applications and uses by the user and by any third party to which yhe user may convey the products. Since Armacell cannot control the end of this product, Armacell does not guarantee that the user will obtain the same results as published in this document. The data and information is provided as technical service, and the data and information are subject to change without notice. info.armaform@armacell.com - Copyright: Armacell Benelux SA. PIGR , Rev02

2 ArmaFORM PET GR: a truly sustainable concept All our ArmaFORM PET foam cores are manufactured according to an energy and resource-optimized production process: > no ozone depleting HFC / CFC blowing agents > only halogen-free flame retarded additives > 100% re-use of material loss during production Additionally our products are fully recyclable at life cycle s end and thus are considered as an environmentally sensitive solution in the composite industry. Compared with common core materials, ArmaFORM PET GR shows an excellent environmental performance regarding global warming potential and energy demand: The use of ArmaFORM PET GR enables Armacell and its customers to present a real green alternative to standard PET foams and other foam core materials currently available in the market. Every kilo of recycled PET flakes used to produce ArmaFORM PET GR reduces CO 2 emission by 63% compared to standard PET foam cores which are made of bottle grade (virgin) PET resin. (source: Delft University of Technology) Life cycle of ArmaFORM PET GR PET material collection Sorting, crushing,... to flakes PET granulation process Extrusion foaming process Use in a variety of applications ArmaFORM can be 100% recycled But we did not stop there and have again made a significant contribution to sustainable growth in the composite industry. Global warming potential (Co 2 ) 260% 209% 185% 179% 149% 100% Scientists of the global R&D Team have spent several years in the development of a technology that enables the production of PET foam boards with consistent, reliable qualities 100% made from post-consumer PET materials, called ArmaFORM PET GR. This green PET foam core fulfills not only stringent technical requirements of composites foam cores but also provides sustainable development and brings measurable environmental and socio-economic benefits. Armacell provides this information as a technical service. To the extent the information is derived from sources other than Armacell, Armacell is substantially, if not wholly, relying upon the other source(s) to provide accurate information. Information provided as a result of Armacell s own technical analysis and testing is accurate to the extent of our knowledge and ability, using effective standardized methods and procedures. Each user of these products, or information, should perform their own tests to determine the safety, fitness and suitability of these products, or combination of products, for any foreseeable purposes, applications and uses by the user and by any third party to which yhe user may convey the products. Since Armacell cannot control the end of this product, Armacell does not guarantee that the user will obtain the same results as published in this document. The data and information is provided as technical service, and the data and information are subject to change without notice. PUR SAN PVC XPS PET standard CO 2 emission per kg foam Cumulative energy demand (MJ) 142% 141% 101% 106% 107% PUR SAN PVC XPS PET MJ per kg foam standard info.armaform@armacell.com - Copyright: Armacell Benelux SA. r-pet 100% r-pet PIGR , Rev02

3 ArmaFORM PET/W GR Polyethylene Terephthalate based structural foam cores. 100% made of post-consumer PET. GR70 GR80 GR100 GR115 GR135 GR150 GR200 GR250 (1) GR320 (1) Density ISO 845 kg/m³ 70 (2) 80 (2) 100 (2) 115 (2) 135 (2) 150 (2) 200 (2) 250 (2) 320 (2) Compression Strength Compression Modulus ISO 844 MPa 0,75 0,95 1,5 1,8 2,3 2,6 3,6 5,0 7,0 ISO 844 MPa Shear Strength (3) ISO 1922 MPa 0,5 0,55 0,75 0,9 1,2 1,4 1,8 1,9 2,1 Shear Modulus (3) ISO 1922 MPa Shear Strain (3) ISO 1922 % Tensile Strength Tensile Modulus Thermal Conductivity ASTM C 297 MPa 1,8 2,1 2,4 2,7 3,0 3,4 4,4 4,5 4,8 ASTM C 297 MPa at 23 C W/mK 0,034 0,034 0,034 0,034 0,037 0,041 0,043 0,047 Fire performance (4) B2 EN ISO 11925:2 B2 (5) B2 (5) B2 (5) B2 (5) B2 (5) B2 (5) Tolerances Length Width Diagonal Thickness Dimensions (mm) (6) (7) GR70-GR80: mm GR100-GR320: 5-150mm Tolerances (mm) at room temperature +/- 5 +/ mm: +/- 0,5 100mm: +/- 1 (1) Preliminary data (indication based on a limited number of tests). (2) Tolerances: +/- 5 kg/m³ (3) // direction (parallel to the weld) (4) For detailed test results and certificates please contact us. (5) As of 50mm. (6) Standard dimension. Further dimensions on special request. (7) Depending on length and width combination. All values are average production figures. Minimum values on request. ArmaFORM PET products are CFC / HFC free. Physical properties are not affected by variances in colour. Customs tariff code: Armacell provides this information as a technical service. To the extent the information is derived from sources other than Armacell, Armacell is substantially, if not wholly, relying upon the other source(s) to provide accurate information. Information provided as a result of Armacell s own technical analysis and testing is accurate to the extent of our knowledge and ability, using effective standardized methods and procedures. Each user of these products, or information, should perform their own tests to determine the safety, fitness and suitability of these products, or combination of products, for any foreseeable purposes, applications and uses by the user and by any third party to which yhe user may convey the products. Since Armacell cannot control the end of this product, Armacell does not guarantee that the user will obtain the same results as published in this document. The data and information is provided as technical service, and the data and information are subject to change without notice. info.armaform@armacell.com - Copyright: Armacell Benelux SA. DSWnm , Rev02

4 Technical Data: June 2015 ArmaFORM PET/E GR: green structural foam core Polyethylene Therephthalate (Extruded) PET/E GR65 PET/E GR75 PET/E GR110 PET/E GR145 PET/E GR195 Density ISO 845 kg/m³ 65 (1) 75 (1) 110 (1) 145 (1) 195 (1) Compression Strength Z-direction Compression Modulus Z-direction Tensile Strength Z-direction Tensile Modulus Z-direction Shear Strength YZ-direction Shear Modulus YZ-direction Shear Elongation YZ-direction Shear Strength XZ-direction Shear Modulus XZ-direction Shear Elongation XZ-direction Thermal Conductivity ISO 844 MPa 0,2 0,3 0,6 1,05 1,8 ISO 844 MPa ASTM C297 MPa 0,55 0,7 1,2 1,5 1,9 ASTM C297 MPa ISO 1922 MPa 0,3 0,4 0,55 0,85 1,25 ISO 1922 MPa ISO 1922 % ISO 1922 MPa 0,3 0,45 0,75 1,1 1,15 ISO 1922 MPa ISO 1922 % at 23 C W/m K 0,029 0,032 Tolerances Thickness Length Width (2) Dimensions (mm) to 5200 up to 1015 (depending on density) Tolerances (mm) at room temperature +/ / +20 +/- 10 (1) Tolerances +/- 5 kg/m³. (2) Please note that the available sizes of non-welded boards are subject to prior discussion. All values are average production figures. Based on extrusion thicknesses mm, with changing extrusion thickness mechanical properties can vary. All ArmaFORM PET products are CFC / HFC free. Armacell provides this information as a technical service. To the extent the information is derived from sources other than Armacell, Armacell is substantially, if not wholly, relying upon the other source(s) to provide accurate information. Information provided as a result of Armacell s own technical analysis and testing is accurate to the extent of our knowledge and ability, using effective standardized methods and procedures. Each user of these products, or information, should perform their own tests to determine the safety, fitness and suitability of these products, or combination of products, for any foreseeable purposes, applications and uses by the user and by any third party to which yhe user may convey the products. Since Armacell cannot control the end of this product, Armacell does not guarantee that the user will obtain the same results as published in this document. The data and information is provided as technical service, and the data and information are subject to change without notice. info.armaform@armacell.com - Copyright: Armacell Benelux SA, subject to changes / (GB)-WW

5 ArmaFORM PET/W FR, GFR Polyethylene Terephthalate based fire retardant structural foam cores. GFR70 (*) FR100 FR150 Density ISO 845 kg/m³ 70 (1) 100 (1) 150 (1) Compression Strength Compression Modulus ISO 844 MPa 0,8 1,5 2,6 ISO 844 MPa Shear Strength ISO 1922 MPa 0,55 0,85 1,3 Shear Modulus ISO 1922 MPa Shear Strain ISO 1922 % Tensile Strength ASTM C 297 MPa 1,6 2,4 3,4 Tensile Modulus ASTM C 297 MPa Thermal Conductivity at 23 C W/mK 0,034 0,034 0,041 Fire performance (2) Railway Vehicles Flammability Smoke density Dripping Toxicity (FED) Edge ignition DIN DIN DIN DIN DIN / DIN S4 SR2 ST2 <0.1 K1 S4 SR2 ST2 <0.1 K1 Railway Vehicles Construction Flammability Smoke density NF F NF F M1** F1 M1*** F1 M1*** F1 Railway Vehicles FST EN (3) conform conform Aviation Flammability Smoke density Toxicity FAR /ABD0031 FAR /ABD0031 FAR /ABD0031 fulfilled fulfilled fulfilled Construction Contribution to fire Smoke production Flaming droplets EN EN EN D s2 d0 Tolerances Length Width Diagonal Thickness Dimensions (mm) (4) (5) 5 150mm Tolerances (mm) at room temperature +/- 5 +/ mm: +/- 0,5 100mm: +/- 1 (*) Preliminary data March 2017 (1) Tolerances: +/- 5 kg/m³ (2) For detailed test results and certificates please contact us. (3) Final sandwich design to be tested. (4) Standard dimension. Further dimensions on special request. (5) Depending on length and width combination. Armacell provides this information as a technical service. To the extent the information is derived from sources other than Armacell, Armacell is substantially, if not wholly, relying upon the other source(s) to provide accurate information. Information provided as a result of Armacell s own technical analysis and testing is accurate to the extent of our knowledge and ability, using effective standardized methods and procedures. Each user of these products, or information, should perform their own tests to determine the safety, fitness and suitability of these products, or combination of products, for any foreseeable purposes, applications and uses by the user and by any third party to which yhe user may convey the products. Since Armacell cannot control the end of this product, Armacell does not guarantee that the user will obtain the same results as published in this document. The data and information is provided as technical service, and the data and information are subject to change without notice. ** Tested at 20 mm. *** As of 15 mm. All values are average production figures. Our products are CFC / HFC free. Only halogen-free flame retarded additives. Physical properties are not affected by variances in colour. Customs tariff code: info.armaform@armacell.com - Copyright: Armacell Benelux SA. DSWnm , Rev04

6 FINISHING OPTIONS ArmaFORM PET ArmaFORM PET foam core sheets are available with a variety of finishing options such as grooving, gridscoring, double contouring and perforation to assist resin flow and air removal or to allow curvature conformability. This document is meant to give you a general overview of the different converting options Armacell is offering today. Further converting options can be discussed with your sales representative. Grooving Gridscoring Double Contour Perforation Thermoforming Document No.: DSCm , Rev00

7 Standard Converting Options ArmaFORM PET (welded) February 2016 Grooving (GR) Groove pattern: 30 x 30 mm Standard board size: 1008 x 1224 mm Width of cut: 25mm: 0,9 mm Minimum foam thickness: 10 mm > 25mm: 1,2 mm Maximum foam thickness: 100 mm Depth of cut: 2,0 mm Gridscoring (GS) Foam is almost cut in 30 mm squares and bonded to lightweight fibreglass scrim on bottom side, creating a flexible core sheet. The boards are not cracked. Grid pattern: 30 x 30 mm Standard board size: 1008 x 1224 mm Width of cut: 25mm: 0,9 mm > 25mm: 1,2 mm Minimum foam thickness: 10 mm 100 kg/m³ 15 mm GR80 15 mm FR100 Maximum foam thickness: 50 mm Double Contour (DC) Both sides of the foam core are cut in both directions to a depth of > 50% of the core thickness, creating a somewhat fexible core sheet. Groove pattern: 30 x 30 mm Standard board size: 1008 x 1224 mm Width of cut: 25mm: 0,9 mm Minimum foam thickness: 15 mm > 25mm: 1,2 mm Maximum foam thickness: 95 mm Depth of cut: > 50% of the foam Perforation (P) Thickness 60 mm Standard board size: 1008 x 1224 mm Hole pattern: 32 x 32 mm 1008 x 2448 mm ** Hole diameter: 3 mm Maximum foam thickness: 140 mm Thickness 60 mm Hole pattern: 32 x extrusion thickness* * Extrusion thickness depending on density 45-85mm. Hole diameter: 5 mm ** Except 250 kg/m³. Scrim (S) Our foam core sheets can be delivered with or without fibreglass scrim. Minimum foam thickness: 10 mm 100 kg/m³ Maximum foam thickness: 150 mm 15 mm GR80 15 mm FR100 Thermoforming (T) Due to its pure thermoplastic nature PET core is well suited for thermoforming to create both two and threedimensional shapes without the stress concentrations in the core. Thermoforming is carried out by heating the PET core to its softening point and forcing it against the contour of a female or male mould. Among others, the final temperature is depending on foam thickness and density, as a starting guidance you can say that thermoforming PET core takes place between C. After the material has cooled down to room temperature the part remains in its new shape with close to zero spring-back effect. info.armaform@armacell.com - Copyright: Armacell Benelux SA, subject to changes / (GB)-WW Document No.: DSCm , Rev00

8 NEW PRODUCT ArmaFORM PET MC: a multi-density PET foam core It is common practice for composite sandwich solutions to combine different densities in one foam core to improve impact and point load resistance and at the same time keeping the weight at its minimum. Bonding the different core material layers together requires the use of adhesives and cutting or perforating the foam sheets, both increasing production costs and adding extra weight. Due to its thermoplastic nature, ArmaFORM PET opens new ways of processing the core into a multi-layered concept: the thermo-welding process. This process provides a uniform and well controlled bond line every time and eliminates the core stress concentration induced by cutting the foam. ArmaFORM PET MC benefits > Better strength-to-weight ratio > Higher impact and point load resistance > Increased sandwich stiffness > Superior screw retention without additional reinforcement > 100% made of recycled PET and 100% recyclable after use phase High density top layer for impact and point load resistance. ArmaFORM PET MC - the combination of different densities in one foam core Low density core for bending strength and stiffness. Dual core ArmaFORM PET MC applications Triple core Multiple core ArmaFORM PET MC is designed to replace traditional Plywood-XPS and other multi-ply panels used in a variety of applications like load bearing floor panels in lightweight trucks and trailers, side wall insulation panels in refrigerated trucks, in modular housing or accessible areas like scaffolding platforms, pedestrian bridges, stage panels and many more. PIMC , Rev01

9 From PET beads to 3D shaped foam parts Armacell continuously creates innovation and now offers particle foams based on PET. This new development enables the manufacturing of ready-to-use parts from foamed PET beads on an industrial scale. Innovative Fusion Technology Starting from recycled PET flakes, the polymer is granulated and further processed by Armacell s patented technology to produce foamed PET beads. A new technology has been developed for the fusion of the loose beads to yield custom shaped ready-to-use foam parts. This novel technology is highly automated and not restricted to a particular density. PET beads combine the high mechanical properties of structural core foams with the advantages of particle foams to offer lightweight and strong three-dimensional foam parts which are producible in nearly any shape. Some of the most interesting and impressive features of PET beads are: Cost-effective manufacturing of 3-D shaped foam parts for serial production Temperature C Longterm Stability Intermittent Exposure The new moulding technology does not require further production steps like milling and avoids any scrap. It is virtually a waste-free production. Additionally, the applicable high service temperature level of up to +180 C can significantly speed up further processing steps since fast curing resins could be employed to equip the foamed part with skins. Finally, by reducing production steps and cycle times, cost benefits can be realized. Microcellular closed cell foam The fine and smooth surface structure provides good adhesion to facing layers and avoids unnecessary resin or additional treatment. PET beads are compatible with all common resin systems and thermoset materials. The homogeneous and small cells ensure unchanged high mechanical properties (compression & shear) over the entire foam part and good insulation properties at the same time EPS EPP PET Beads Figure 1: Temperature Stability (ºC) Figure 2: Cell Size (µm) PIBeads , Rev05

10 Sustainability PET beads are manufactured and processed in an ecofriendly manner without using FCHCs. Furthermore, grades with tailored fire retardancy characteristics have been developed which employ the newest generation of halogen-free flame retardants. Being made from 100% recycled PET and recyclable again after their use phase, PET beads represent a highly sustainable alternative to comparable materials in the market. Preliminary technical data Density ISO 845 kg/m³ 200 * Compression Strength (10 % deformation) Compression Strength (25 % deformation) ISO 844 MPa 1,26 ISO 844 MPa 1,71 Compression Modulus ISO 844 MPa 28,31 Shear Strength ISO 1922 MPa 0,79 Shear Modulus ISO 1922 MPa 21,77 Shear Elongation ISO 1922 % 3, 6 Tensile Strength ISO MPa 0,5 * Further densities under development. Please contact us for more information. Sustainability Our offer Mechanical Properties Insulation Properties High mechanical properties Superior temperature resistance Temperature Resistance Surface Quality Tailored fire properties Good resistance to chemicals & oils Freedom of design Fire Properties Part Weight Material Cost Closed-cell structure Good insulation properties Made from 100% made from recycled PET PET Beads PMI EPP 100% recyclable after use-phase Armacell provides this information as a technical service. To the extent the information is derived from sources other than Armacell, Armacell is substantially, if not wholly, relying upon the other source(s) to provide accurate information. Information provided as a result of Armacell s own technical analysis and testing is accurate to the extent of our knowledge and ability, using effective standardized methods and procedures. Each user of these products, or information, should perform their own tests to determine the safety, fitness and suitability of these products, or combination of products, for any foreseeable purposes, applications and uses by the user and by any third party to which yhe user may convey the products. Since Armacell cannot control the end of this product, Armacell does not guarantee that the user will obtain the same results as published in this document. The data and information is provided as technical service, and the data and information are subject to change without notice. info.armaform@armacell.com - Copyright: Armacell Benelux SA. PIBeads , Rev05